Perma-stitch awning staple system

ABSTRACT

A system using a specially designed frame/support member for manufacturing awnings and coverings and other-type sign assemblies without the use of traditional sewing. This system incorporates a special frame/support member that has a rounded channel that allows the covering material to be pulled taunt and stapled to the frame within the channel. The staples are then hidden by a flexible, round bead. The bead is constructed from such material that it can be covered with the same covering material or fabric that makes up the main body of the assembly. The covered bead is inserted into the support member channel in such a way that only a small section of the bead is visible and does not protrude from the channel.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is entitled to the benefit of the Provisional Patent Application Ser. No. 60/555,228 filed on Mar. 23, 2004.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH and DEVELOPMENT

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to the manufacturing and installation of commercial and residential awnings and other framing structures. The present invention allows awnings to be installed as a series of individual sections, yet appear continuous and seamless to the eye. In the awning industry today, the maximum size of an awning section is constrained by the dimensions of the pre-manufactured cover material.

2. Description of Prior Art

The major manufacturer of awnings and awning accessories uses the technology described in U.S. Pat. No. 4,926,605 issued in 1990 to Milliken et al and U.S. Pat. No. 5,044,131 issued in 1991 to Fisher. Both patents disclose and teach an awning assembly that has an essentially square channel and includes a bead or connecting joint that is plastic. In each of the referenced patents, the bead or connecting joint taught protrudes above the upper boundary of the channel or seam. The utilization of the prior art is applicable when more than one frame member is used because the awning or covering has to be constructed from more than one section.

Another example of prior art is U.S. Pat. No. 5,076,033 issued to Pasty in 1991. This patent teaches a method of combining frame/support members with a clamp, thus introducing an additional piece of hardware to complete the task. Again, the prior art either utilizes or makes allowances for the use of the plastic bead that extends over the surface of the frame/support member.

SUMMARY OF THE INVENTION

This invention is a new, improved frame/support member, construction assembly and method for constructing awnings and other covers which are wrinkle-free and appear continuous and seamless from the normal viewing range.

OBJECTS AND ADVANTAGES

This inventions allows uniform weathering of all visible parts of an awning or other covering. It creates a more aesthetically-pleasing awning or covering because the sections are joined without an element protruding above the surface of the frame. Further, the present invention eliminates the current practice of having a different material showing at various intervals when an awning is made from more than one section.

Additionally, the invention claimed in this application allows a seal between sections which is light- and water-tight without requiring additional parts. Further objects and advantages of this invention will become apparent from a consideration of the drawings and ensuing description.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a side perspective view of the perma-stitch awning staple system wherein the covering material only extends from one side of the channel and the bead is concealed within the same covering material.

FIG. 2 is a side view of the perma-stitch awning staple system wherein the covering material extends from both sides of the channel and the bead is concealed within the same covering material.

FIG. 3 is a front sectional perspective view of a construction assembly wherein two sections built using the perma-stitch system embodied in FIGS. 1 and 2 are connected using the method claimed herein to create a larger covering.

FIG. 4 is a side perspective view of the perma-stitch awning staple system wherein two sections are connected to create a larger covering.

REFERENCE NUMBERS IN DRAWINGS

-   20 elongated frame/support member -   21 first side member -   22 second side member -   23 base member -   24 first adjacent wall -   25 second adjacent wall -   30 circular-shaped channel -   31 channel surface wall -   40′ staple -   50 a/50 b trim notch -   60 bead -   61 bead opening -   70 covering material -   80 bead encasement -   90 generic tubing -   100 construction assembly

DETAILED DESCRIPTION OF THE INVENTION

A frame/support member 20 composed of a first 21 and second 22 side member and a bottom member 23 with an essentially circular-shaped channel 30 oriented opposite the bottom member 23 and connected to the first 21 and second 22 side member with a first 24 and second 25 adjacent wall, respectively, with at least one trim notch on the left 50 a and right 50 b inside surface channel 31.

A construction assembly 100 for use in creating awnings or other type covering which is comprised of at least one frame/support member 20; a flexible material 70 suitable for use as an awning or other type covering; at least one connecting staple 40′ capable of piercing said covering material 70 and securely affixing said covering material 70 to the inside channel surface 31; a bead 60 of the appropriate diameter and length to fit securely in the channel 30 which is inserted through the bead opening 61 secured by first 24 and second 25 adjacent wall, said bead composed of such material to be capable of being fully covered within the bead encasement 80 which is made of said covering material 70.

A method for constructing a composite awning or other covering assembly composed of at least one construction assembly 100 and a flexible material 70 whereby the said awning 100 appears to be one piece from a minimal viewing distance.

The preferred embodiment of the invention is generally shown in FIG. 4. FIG. 4 illustrates a composite awning which is constructed by combining two separate construction assemblies, each of which is made using the claimed frame/support member 20 on the adjoining terminal ends of each section construction assembly. While this invention has been described in detail with reference to the preferred embodiment, numerous variations can be made within the spirit and the scope of the invention as described herein. 

1. An elongated joinable frame/support member composed of a) a first and second side member; and b) a bottom member with c) a circular-shaped channel oriented opposite the bottom member and connected to the first and second side member by a first and second adjacent wall; and d) at least one trim notch disposed on the left or right channel surface wall.
 2. A construction assembly for attaching a flexible covering material to a fixture comprising at least one support member as defined in claim 1; a covering material; at least one staple or other fastening mechanism to anchor the covering material to the support member.
 3. A construction assembly for attaching a flexible covering material to a fixture comprising at least one support member as defined in claim 1; a covering material; at least one staple or other fastening mechanism to anchor the covering material to the support member; at least one elongated bead of the length and diameter to lock itself and the covering material into the circular channel of said support member without protruding above the surface.
 4. A construction assembly for attaching a flexible covering material to a fixture comprising at least one support member as defined in claim 1; a covering material; at least one staple or other fastening mechanism to anchor the covering material to the support member; at least one elongated bead of the length and diameter to lock itself and the covering material into the circular channel of said support member without protruding above the surface wherein the bead is encased in the covering material.
 5. A method for constructing an awning or other covering comprising at least two construction assemblies as defined in claim 2 wherein the right-most frame/support member of the left construction assembly is oriented such that the channel is at a 90 degree angle and the left-most frame/support member of the right construction assembly is oriented such that the channel is at a 270 degrees with respect to the visible section of the awning. 